Process for preparing supported catalysts

ABSTRACT

A process for preparing a catalyst comprising a metallic catalytic agent on a particulate carrier is disclosed which provides improved uniformity of distribution and fineness of division with narrowness of particle size distribution of the metallic catalytic agent on the carrier. The carrier is impregnated with an aqueous solution of a salt of the metallic catalytic agent and of a source, on heating in aqueous solution, of hydroxyl ions. The impregnated carrier is heated without substantial loss by evaporation of the aqueous solution to precipitate the metal or the particles with uniformity of distribution and fineness of division with narrowness of particle size distribution. The metal is converted by conventional methods to the appropriate active, oxidized or reduced, state. The process is particularly significant with carriers, such as alumina and silica, that in alkaline media are liable to undergo structural charges.

[451 ,ian.25,fi972 PROCESS FOR PREPARING SUPPORTED CATALYSTS [72] Inventors: Wilhelmus Petrus Van Beek; Theo Jan 0singa, both of Vlaardingen, Netherlands Lever Brothers Company, New York, NY.

[22] Filed: Apr. 6, 1970 [21] Appl.No.: 26,099

[73] Assignee:

[30] Foreign Application Priority Data Apr. 9, 1969 Luxembourg ..58,392

[52] US. Cl ..252/459, 252/440, 252/454, 252/466, 252/472, 252/473 [51] lnt.Cl. ..Btllj 11/24 [58] Field of Search ..252/430, 466 J, 472, 459, 473, 252/440, 454

[56] References Cited UNITED STATES PATENTS 3,207,702 9/1965 Flank et al. ..252/459 X 3,320,182 5/1967 Taylor et a1. ..252/466 J FOREIGN PATENTS OR APPLICATIONS 6,705,259 [OH 968 Netherlands ..252/466 J Primary Examiner-Patrick P. Garvin AtmrneyLouis F. Kline, .lr., Melvin H. Kurtz and Edgar E. Ruff [5 7] ABSTRACT A process for preparing a catalyst comprising a metallic catalytic agent on a particulate carrier is disclosed which provides improved uniformity of distribution and fineness of division with narrowness of particle size distribution of the metallic catalytic agent on the carrier. The carrier is impregnated with an aqueous solution of a salt of the metallic catalytic agent and of a source, on heating in aqueous solution, of hydroxyl ions. The impregnated carrier is heated without substantial loss by evaporation of the aqueous solution to precipitate the metal or the particles with uniformity of distribution and fineness of division with narrowness of particle size distribution. The metal is converted by conventional methods to the appropriate active, oxidized or reduced, state. The process is particularly significant with carriers, such as alumina and silica, that in alkaline media are liable to undergo structural charges.

5 Claims, No Drawings PROCESS FOR PREPARING SUPPORTED CATALYSTS The present invention relates to a process for the production of a catalyst, which catalyst consists of a metallic catalytic agent in a porous carrier, and to catalysts obtained in this way.

Catalysts which consist of a metallic catalytic agent in a porous carrier have been known for many years. They are often referred to as supported catalysts. The efficiency of such catalysts depends on a number of properties, such as activity, resistance to poisons, resistance to sintering and selectivity.

It has been found that such properties can be enhanced by using processes for the preparation of the catalyst which improve the uniformity of distribution, fineness of division and narrowness of particle size distribution of the catalytic agent in the porous carrier.

The activity of catalyst depends primarily on the surface area of the catalytic agent in relation to weight of catalyst, which surface must be easily accessible. Uniformity of distribution, fineness of division and narrowness of particle size distribution reduce the likelihood of the particles of metallic catalytic agent coalescing in the carrier. Coalescing is disadvantageous because it reduces the surface area and hence the activity of the metallic catalytic agent.

Also when for full activity the metallic catalytic agent has to be activated by reduction, the final activity depends on the amount of metallic compound reduced during activation. This quantity depends on the physical and chemical state, in particular on uniformity of distribution and fineness of division, of the metallic compound in the carrier.

As with activity, resistance to poisons is affectedby the surface area of the catalytic agent. In general the larger the surface area the greater the resistance to poisons, i.e., the more poison required to make the catalyst inactive.

Resistance to sintering similarly depends on uniformity of distribution and fineness of division. Resistance to sintering is particularly important when high temperature activation, for example high-temperature reduction, is necessary. Usually the degree of reduction achieved is greater at higher reduction temperatures. In general with catalysts with high resistance to sintering a higher active surface area can be retained than with catalysts whose resistance to sintering is lower.

In various catalytic processes it is important for the catalyst used to have a high selectivity. For example, in hydrogenation processes, in which two or more double linkages are hydrogenated successively, it is important that hydrogenation is carried out in successive stages in order to obtain partially hydrogenated compounds which are free from more saturated compounds. This selectivity depends on the structure of the catalysts as well as on the nature of the catalytic agent. Thus, for the selective hydrogenation of triglycerides derived from polyunsaturated fatty acids, catalysts with a nickel or copper base are often used, each of which has a specific and different selectivity for this type of hydrogenation. Usually this selectivity increases with the dimension of the pores of the carrier. When these catalysts are produced, it is preferred to start with a carrier whose pores have the required dimension and whose structure is maintained as far as possible throughout these operations. Uniformity of distribution, fineness of division and narrowness of particle size distribution aid maintenance of the required dimensions and structure.

A great many processes for the preparation of such catalysts mounted on carriers have been proposed. The most significant proposals can be classed as follows.

First, processes in which a hydroxide of the catalytic agent is precipitated from an aqueous solution of one of its salts on to the carrier in suspension in this solution by the addition of a basic compound, such as an alkaline carbonate or hydroxide or ammonia. Then the carrier bearing the hydroxide precipitated from the aqueous solution is separated, after which it is washed, if necessary, and dried. The disadvantage of such processes is that a significant proportion of the catalytic agent fails to be precipitated on to the carrier. Furthermore, the quality of the catalysts prepared in this way depends not only on the nature of the reagents but also on the way they are added and the pH and temperature conditions during their addition. it is very difficult, especially on an industrial scale, to obtain catalysts of constant quality.

According to a second type of process, the carrier is impregnated with an aqueous solution of a salt of a metallic catalytic agent, preferably a nitrate, then the impregnated mass is dried and heated to a high temperature to decompose the salt and form the metallic catalytic agent, i.e., corresponding oxide or the free metal. Such a process has the advantage of being easy to carry out and can be carried out in relatively small apparatus in view of the small volume to be treated. It has, however, the major disadvantage that during drying, the aqueous solution containing the salt moves to the outer surface of the carrier so that the catalytic agent is not uniformly distributed in the catalyst obtained.

Both types of process have the disadvantage that it is practically impossible for the catalytic agent to be deposited very finely and with narrow particle size distribution.

In further proposed processes the metal is precipitated from solution on to the carrier by allowing hydroxyl ions to develop in this solution and not by adding such ions as above. German Pat. No. 740,634 describes such a process in which an aqueous solution containing a suitable salt of a metal and urea or a similar nitrogen compound is heated with a carrierv Heating brings about the decomposition of the urea, the pH of the solution is increased by the effect of the freed ammonia and the metal is precipitated on the surface of the carrier particles. Netherlands Pat. application No. 6705259 describes such a process in which the precipitation is effected by using a suspension of the carrier in an aqueous solution of the metal salt and urea. According to German Pat. No. 740,634 this process can in addition be used for systems in which the carrier is impregnated with the aqueous salt and urea solution and then heated.

Such an impregnation process has the advantages over a suspension process that smaller quantities of liquid can be used, simpler apparatus can be used and the procedure is simplified (for instance, no or improved filtration). Although German Pat. No. 740,634 states that when the disclosed process is used even as an impregnation process, no migration of the salt towards the outer surface of the carrier is observed, in practice as with the impregnation process described above (second type of process), the catalytic agent is not distributed entirely uniformly over the carrier. Also the desired fine particle form is only partially obtained.

The aim of the present invention is to provide a process which, while substantially preserving the advantages of the impregnation process, i.e., comparative ease of execution, simple apparatus and small volume, gives improved unifomi distribution and fineness of division with narrow particle size distribution of the catalytic agent in the carrier.

According to the invention, a catalyst which consists of a metallic catalytic agent in a porous carrier is prepared in which the catalytic agent is distributed uniformly and in a finely divided state with narrow particle size distribution in the carrier, by impregnating the carrier with an aqueous solution of a salt of the catalytic agent and of a source, when heated in aqueous solution, of hydroxyl ions; and heating the impregnated carrier to allow sufficient hydroxyl ions to develop to precipitate the metal without substantial loss by evaporation of the aqueous solution.

Evaporation can be avoided by heating the impregnated carrier in an atmosphere the partial water vapor pressure of which is approximately equal to that of the impregnated carrier. Too great a difference between the partial water vapor pressures would lead to condensation of water. This would cause an undesirable dilution of the carrier. It has been found that undesirable condensation can be almost completely avoided by using an atmosphere where the partial water vapor pressure exceeds that of the impregnated carrier by 0 to 200 and preferably 0 to mm. Hg, although acceptable results can still be obtained with greater differences in partial pressure.

The water vapor giving the required partial pressure can originate either from the water in the impregnated carrier itself or from extraneous water. In the latter case, for example, water vapor having the required partial pressure can be passed over the carrier. For reasons of convenience, water vapor with a pressure of 1 atmosphere is used and the impregnated carrier is heated to 90l00 C. This process lends itself particularly well to a continuous method. For example, the carrier can be conveyed with the aid of a screw or other device in a pipe, making sure that there is sufficient free space for the passage of gas between the conveying device or the conveyed impregnated carrier and the wall of the pipe. The carrier is brought to the required temperature while it is being conveyed in the pipe, and simultaneously steam passes into the remaining free space.

An alternative system for ensuring that substantially no loss occurs of the aqueous solution by evaporation is to allow the hydroxyl ions to develop in a sealed vessel. This ensures that water vapor formed does not escape freely thus causing the desiccation of the impregnated carrier which must be avoided. The vessel can be sealed in various ways. Thus the vessel can be completely gastight, in which case an autoclave or similar apparatus capable of resisting the high levels of pressure attained must be used. Alternatively, sufficient impermeability can be ensured by use of a piston flap valve system or a similar system which allows carbon dioxide or any other gas liberated, for example by decomposition of the nitrogen compound, to be released into the atmosphere. Part of the steam is of course carried along but this release can be limited to a permissible degree by ensuring that the valve or piston system closes under a given pressure, for example, by means ofa spring.

In a further alternative for making the heating space sufficiently impermeable, the impregnated carrier itself is used as a sealant. In this last case, a process according to which the carrier is conveyed continuously through an oven at a suitable temperature can also be used to advantage. Preferably there the free space between the inside wall of the oven and the impregnated carrier should be kept to a minimum. It is possible for an excessive quantity of water to evaporate from that part of the impregnated carrier which first passes into the heated zone, so that this portion has to be rejected, but for the following carrier this is substantially not the case, because the first portion constitutes a large enough obstacle to the atmosphere. If desired such an apparatus can be equipped with a valve or similar system so that the impregnated carrier leaves the apparatus under counterpressure.

It should be noted that the term impregnated carrier" here means a homogeneous system obtained by mixing the solid carrier and the aqueous solution in which system all the carrier is moistened but without agitation separate solid and liquid phases cannot readily be detected.

The appropriate amount of aqueous solution to use for a given carrier will depend on the particular nature of the carrier but can readily be determined by experiment: the same amount of carrier as to be used in a process according to the invention is tested with distilled water to determine the quantity of water that moistens all the carrier so that addition of further water causes a separate liquid layer to form. This quantity is the quantity of aqueous solution to be used but with two qualifications.

First, some carriers, in particular some silicas, show an increasing capacity for absorbing water when stood in water. For such carriers both the quantity of distilled water that initially moistens the carrier and the quantity that fully saturates the carrier should be determined. Both should be such that addition of further water causes a separate liquid layer to form. The quantity of aqueous solution to be used is any quantity from the initial to the saturated quantity.

Secondly, the process of the invention can also be applied to systems containing a certain excess of liquid. It is even an advantage to use such systems in cases where the water vapor having the required partial pressure originates from the impregnated carrier, in order to avoid part of the impregnated carrier drying up, since this is undesirable when trying to obtain a catalyst of the undesired quality. The process of the invention can therefore also be used for systems containing more aqueous solution than the quantity determined above but the thickness of the liquid phase initially above the impregnated carrier in the process of the invention must not exceed 5 mm.

Metallic catalytic agent here means a metal that has or promotes catalytic activity in the reduced or oxidized state.

Examples of the metal that can be prepared according to the invention include beryllium, copper, gold, zinc, cadmium, mercury, aluminum, titanium, zirconium, hafnium, germanium, tin, lead, vanadium, niobium, tantalum, antimony, bismuth, chromium, molybdenum, tungsten, manganese, iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium, platinum, thorium, uranium and rare earth metals. Textbooks and general literature provide copious illustrations of catalysts that consist of metallic catalytic agents in porous carriers. Reference can be made for example to Catalysis," Ed. Emmett, particularly Chap. I, Vol. II, 1955, Reinhold.

Suitable carriers are well known in the literature. Examples include diatomaceous earths (e.g., kieselguhr), pumice, porcelain, silica, asbestos, alumina, charcoal, kaolin, other silicates, infusorial earth, magnesium and barium sulfates and magnesia. Typical surface areas of such carriers lie within the range of 4 to 1,000 sq.m.lg.

The process of the invention is particularly advantageous for the production of catalysts in which the carrier is insufficiently stable in alkaline conditions, as in the case of silica and alumina. In the generally acid conditions of the process according to the invention, structural changes in silica and alumina are much less likely than in proposed processes.

Silica or alumina catalysts, useful for instance for the selective hydrogenation of polyunsaturated triglycerides, and should preferably have pores mainly with a diameter of more than 25 A. and preferably more than A. A particular advantage of the invention is that catalysts with such pore structure can be prepared consistently.

Which salt of the metal to use in the process of the invention is mainly determined by the solubility of the salt in water. Water solubilities are given, for example, in Handbook of Chemistry and Physics," Chemical Rubber Publishing Co. To prepare catalysts with a high-catalytic agent content an aqueous solution with a high concentration of a salt of the required catalytic metal should preferably be used. If no sufficiently soluble salts are available, precipitation can be repeated one or more times. A second factor which influences the choice of metal salt to be used as if washing of the carrier bearing the metallic catalytic agent is required before drying. in industrial production of catalysts it is important to simplify the process as much as possible and therefore not to wash. So a salt should be used which leaves no residue in the catalyst which could have an adverse effect on its properties.

It should be noted that the metallic catalytic agent can be a mixture. A catalyst containing such a mixture can be prepared according to the invention either by using a mixture of salts or more than one precipitation.

There are many convenient sources of hydroxyl ions. All that is required is that hydroxyl ions develop on heating and that the source of hydroxyl ions is water-soluble. Particularly convenient as sources of hydroxyl ions are organic nitrogen compounds that hydrolize when heated in an aqueous medium to form ammonia or primary or secondary amines. Examples of appropriate compounds of this type are urea, but other amides, such as formamide, dimethylformamide, dimethylacetamide and acetamide, are also suitable.

Compounds which are particularly suitable have the general formula:

where R and R each independently are hydrogen or a C to C, alkyl group or, when taken together, are (CI-I (CH or (CH O-(CH X is O or NH; and R is H, or C to C a1kyl group or -NRR Another substance which can be used to provide hydroxyl ions is hexamethylene tetramine.

The metal is usually precipitated on the surface of the carrier particles in the form of a hydroxide but sometimes it is preferable to precipitate it in the form of a basic salt, in which case it is advisable to see that the solution contains anions of a suitable acid. These anions can be present just as they are in the aqueous solution e. g., in the form of a catalytic metal salt) or they can be formed during the same decomposition process which liberates the hydroxyl ions. Basic salts which can be precipitated in this process are, for example, basic iron formate(l11) in which case the formate ions can for example be formed by means of formamide as the source of hydroxyl ions. Because metal salts are usually expensive, complete or almost complete precipitation of the metal is preferred. Prior proposals have required the use of a considerable excess of the source of hydroxyl ions to the metal salt. The amount used, except on basis of the cost of the source of hydroxyl ions, is not critical and, for instance, times the theoretically necessary quantity of the source of the hydroxyl ions can be used.

In a preferred form of the present invention a sealed vessel is used and the temperature used, for instance to decompose urea or like nitrogen compound, is greater than 100 C. Such a preferred form of the invention has a particular advantage that only slight, if any, stoichiometric excess of source of hydroxyl ions need be used, i.e., ratio of source to metal from 1 to 4:1. This is in addition to the advantages of shorter time and smaller vessels than in other processes.

When the source of hydroxyl ions is, for example, a nitrogen compound, the temperature to which the impregnated mass must be heated to decompose the compound depends on its nature. Usually, this temperature is at least 50 C. but it should preferably be higher. When the process is carried out in a system in which there is low-excess pressure, if any, the heating temperature is preferably 85 to 100 C. 1n the case of apparatus which allows a fairly high application of excess pressure, the impregnated carrier is preferably heated to an even higher temperature, which greatly speeds up the process. The temperature to be applied in this case depends on the pressure required in the system, but it is usually between 100 and 200 C., although higher temperatures are still acceptable.

After the metal has been precipitated on the surface of the carrier particles, in the form for example of its oxide, hydroxide or basic salt, it is necessary to ensure that it is in the form in which it best displays the appropriate catalytic activity. Various metals are active as oxides or in the free or reduced state. The appropriate form for each metal catalyst is very well known as are ways of converting the precipitate into the appropriate form. Any general inorganic textbook is a suitable guide. In general it will be necessary to dry the carrier containing the precipitate. As indicated above a washing step prior to the drying step can also be included.

Some metals are active as prepared in the oxidized or reduced state but often an activation step is advisable. Suitable activation processes are very well known as is indicated for instance in Kirk Othmer Encyclopedia of Chemical Technology, Interscience, 1949, Vol. 3, page 267. Examples include thermal treatment at temperatures of 120 to 800 C. and reduction, also often at high temperatures, by means of hydrogen or other reducing agents.

Such activation processes can sometimes be performed without an intermediate drying step, i.e., on the carrier still impregnated with water. Alternatively the carrier particles with the precipitate can be dried, often after washing, and then activated. Activation can also occur, either of dried carrier or of carrier impregnated with water, in a reaction medium on which the catalyst is to act.

Because of this and because the quality of catalysts often diminishes rapidly on storage and because activated catalysts are often pyrophoric, it is often preferable to present the catalysts for storage or for sale, for example, in the nonactivated state. The term catalyst" used herein therefore means activated catalyst, catalysts that do not require activation before use and nonactivated catalysts that require activation before use.

The invention is illustrated by the following examples (according to the invention) and comparative experiments (not according to the invention):

EXPERIMENT A 15.4 ml. of 3.4 N sodium carbonate were added to a boiling suspension of 20 g. of good quality kieselguhr (93.1 percent ash) in 700 ml. of distilled water immediately followed by the simultaneous addition of 400 ml. of a 10 percent aqueous solution of nickel nitrate and 400 ml. of 3.4 N sodium carbonate. The latter solutions were added at a rate of 2 ml. each per minute, while boiling the reaction mixture continuously during the addition. The final mixture was filtered and the filter cake was washed repeatedly with hot water and dried to give a catalyst having a nickel content of 42.6 percent. The catalyst obtained was activated by reducing it for 4 hr. in a tube furnace at 450 C. and in a hydrogen flow of 60 1./hr./g. nickel.

EXPERIMENT B A mixture of 62.9 g. of spherical amorphous silica having a specific surface of 170 m per gram and g. of nickel nitrate was ground in a ball mill for 15 min., after which it was placed in a closed, stoppered bottle and heated for 4 days in an oven at a temperature of 75 C. After this melting procedure the mixture was ground again in a ball mill for 15 min. and then decomposed in a nitrogen flow (60 l./hr.) at 300 C. The resulting catalyst, containing 21.8 percent of nickel, was activated as described in experiment A.

EXPERIMENT C To a stirred suspension of 50 g. of a spherical amorphous silica of the same quality as described in example In, an ammoniacal solution containing 75 g. of nickel nitrate Ni(NO ,,-6H Oand having a pH of 9.5 (measured at 20 C.) was added. The suspension with a total volume of 1,000 ml. was boiled for 2 hr. with vigorous stirring. At the end of this period the pH of the suspension was equal to 6 (measured at 100 C.). After filtration the filter cake was washed repeatedly with cold water and dried at C. during 4 hr. and at 200 C. during 16 hr. to give a catalyst with a nickel content of 19.1 percent.

The catalyst thus obtained, containing 19.4 percent of nickel, was activated by heating it in a stream of hydrogen for 4 hr. at 450 C.

The properties of the activated catalysts of experiments A, B and C are shown in table 1.

EXAMPLE 1 50 g. of spherical amorphous silica carrier with a specific surface of 200 sq.m.lg. are intimately mixed with a solution of 35 g. of nickel nitrate [Ni(NO -6H O] and 29 g. of urea in 360 ml. of water.

The impregnated carrier obtained was put into a small 250- ml. dish whose upper opening, which had a surface of about 7 sq. cm., was covered by a glass plate of about 37 g. in weight. The whole was put into an oven and heated for hr. at 88 C. After heating, the carrier bearing the precipitate was dried first for 16 hr. at 120 C., then for 16 hr. at 200 C. to give a catalyst which had a nickel content of about 10.3 percent by weight.

The catalyst was then heated for 4 hr. at 450 C. in a current of hydrogen in order to activate it. The properties of the activated catalyst thus obtained are shown in table 1.

, EXAMPLE 2 An impregnated carrier, prepared as in example 1, from a solution of 35 g. of nickel nitrate and 29 g. of urea in 360 ml. of water and 50 g. of spherical amorphous silica (specific surface 200 sq.m./g.) was placed in a long trough-shaped boat which was then placed in a glass tube open at both ends. The whole was heated in a tubular oven for 20 hr. at 95 C. while steam was passed through the glass tube. After heating, the mass obtained was dried first for 16 hr. at 120 C. and then for 16 hr. at 200 C. to give a catalyst with nickel content of about 9.6 percent by weight. This catalyst was then activated as in example 1.

The properties of the activated catalyst obtained are shown in table 1.

EXAMPLE 3 An impregnated mass prepared as described in example 1 was placed in a thick-walled glass tube sealed at the ends and heated for hr. in an oven at 125 C. After the tube had been cooled and opened, the mass obtained was dried first for 16 hr. at 120 C., then for 16 hr. at 200 C., to give a catalyst with a nickel content of 9.8 percent by weight. The catalyst was activated as described in example 1. The properties of the activated catalyst obtained in this way are shown in table 1.

EXAMPLE 4 After mixing 50 g. of a spherical amorphous silica, having a specific surface of 200 sq.m./g., with a solution of 70 g. of nickel nitrate (Ni(NO '6H O) and 54 g. of urea in 305 ml. of distilled water, the impregnate obtained was placed in a glass bottle (diameter of the opening 9.3 sq. cm.) covered with a glass plate of the same diameter and a weight of 38.5 g. The closed bottle was heated for 92 hr. in an oven at 92 C. The carrier containing the precipitate was dried for 6.5 hr. at 120 C. and then for 1 16 hr. at 200 C. to give a catalyst having a nickel content of 19.0 percent. The catalyst was activated by reducing it for 4 hr. in a tube furnace at 450 C. and a hydrogen flow of 60 l./hr./g. nickel. The properties of this activated catalyst are shown in table 1.

EXAMPLE 5 After mixing 100 g. of a spherical amorphous silica, having a specific surface of 200 sq.m./g., with a solution of 70 g. of nickel nitrate [Ni(NO 6l-l O] and 120 g. of urea in 630 ml. of distilled water, a H. autoclave was filled for 50 percent of its volume with the impregnate obtained. The closed autoclave was gradually heated during 40 min. to a maximum temperature of 160 C. This temperature was maintained during 30 min., after which the autoclave was cooled to 70 C. over 100 min. The maximum pressure observed was 19 atm. Then the impregnate was removed from the autoclave, and dried for 20 hr. at 200 C. to give a catalyst having a nickel content of9.8 percent.

Activation of this catalyst was achieved by reducing it for 4 hr. in a tube furnace at 400 C. and in a hydrogen flow at a rate of 60 l./hr./g. nickel. The properties of the activated catalyst are shown in table 1.

EXAMPLE 6 After mixing 100 g. of a spherical amorphous silica, having a specific surface of 200 sq.m./g., with a solution of 70 g. of nickel nitrate [Ni( NO '6H O] and 60 g. of urea in 800 ml. of distilled water, a H. autoclave was filled for 50 percent of its volume with the impregnate obtained.

The closed autoclave was gradually heated during 48 min. to a maximum temperature of 155 C. This temperature was maintained during 14 min., after which the autoclave was cooled to 50 C. over 138 min. The maximum pressure observed was 6 atm. Then the impregnate was removed from the autoclave, and dried for 24 hr. at 200 C. to give a catalyst having a nickel content of9.7 percent.

Activation of this catalyst was achieved by reducing it for 4 hr. in a tube furnace at 450 C. and in a hydrogen flow at a rate of 60 l./hr./g. nickel.

The properties of the activated catalyst are shown in table 1.

EXAMPLE 7 After mixing g. of a spherical amorphous silica, having a specific surface of 200 sq.m./g., with a solution of g. of nickel nitrate [Ni(NO -6H O] and 47 g. of urea in 800 ml. of distilled water, a H. autoclave was filled for 75 percent of its volume with the impregnate obtained. The closed autoclave was gradually heated in 43 min. to a maximum temperature of 175 C. during which the maximum pressure observed was 16 atm. Then the impregnate was removed from the autoclave via a valve, cooled and dried for 64 hr. at 200 C. to give a catalyst having a nickel content of 18.1 percent. Activation of this catalyst was achieved by reducing it for 4 hr. in a tube furnace at 450 C. and in a hydrogen flow at a rate of 60 l./hr./g. nickel. The properties of the activated catalyst are shown in table 1.

EXAMPLE 8 After mixing 100 g. of a spherical amorphous silica, having a specific surface of 200 sq.m./g., with a solution of 150 g. of nickel nitrate [Ni(NO -6H O] and 47g. of urea in 800 ml. of distilled water, a H. autoclave was filled for 75 percent of its volume with the impregnate obtained. The closed autoclave was gradually heated in 43 min. to a maximum temperature of 175 C. during which the maximum pressure observed was 16 atm.

The autoclave was then cooled to 50 C. over 60 min. after which the impregnate was removed from the autoclave, washed with hot water and dried for 64 hr. at 200 C. to give a catalyst having a nickel content of 18.7 percent. Activation of this catalyst was achieved by reducing it for 4 hr. in a tube furnace at 400 C. and in a hydrogen flow at a rate of 60 l./hr./g. nickel. The properties of the activated catalyst are shown in table 1.

EXAMPLE 9 After mixing 75 g. of a spherical amorphous silica, having a specific surface of 200 sq.m./g., with a solution of 112.5 g. of nickel nitrate [Ni(NO '6H O] and 36 g. of urea in 600 ml. of distilled water, a 1-1. autoclave was filled for 75 percent of its volume with the impregnate obtained. The closed autoclave was gradually heated in 52 min. to a maximum temperature of 140 C. This temperature was maintained during 9 min., after which the autoclave was cooled to 50 C. over 98 min. The maximum pressure observed was 13 atm. Then the impregnate was removed from the autoclave, washed with hot water and dried for 48 hr. at 200 C. to give a catalyst having a nickel content of 16.0 percent. Activation of this catalyst was achieved by reducing it for 4 hr. in a tube furnace at 450 C. and in a hydrogen flow at a rate of 60 l./hr./g. nickel. The properties ofthe activated catalyst are shown in table 1.

EXAMPLE 10 After mixing 75 g. of a macroporous silica, having a specific surface of 290 sq.m./g., with a solution of 112.5 g. of nickel nitrate [Ni(NO -6H- O] and 36 g. of urea in 300 ml. of distilled water, a H. autoclave was filled for 50 percent of its volume with the impregnate obtained. The closed autoclave was gradually heated in 57 min. to a maximum temperature of C. during which the maximum pressure observed was 1 1.5 atm.

Then the impregnate was removed from the autoclave via a valve, cooled and dried for 24 hr. at 200 C. to give a catalyst having a nickel content of 19.8 percent. Activation of this catalyst was achieved by reducing it for 4 hr. in a tube furnace at 450 C. and in a hydrogen flow at a rate of 60 l./hr./g. nickel. The properties of the activated catalyst are shown in table 1.

2., EXAMPLE I l After mixing 75 g. of a macroporous silica, having a specific surface of 290 sq.m./gl, with a solution of 409 g. of nickel nitrate [Ni(NO '6H O] and 93 g. of urea in 300 ml. of

1 minute per gram of nickel.

8. These measurements showed that a proportion of the crystallites was I A. in size.

. distilled water, a H. autoclave was filled for 75 percent of its EXAMPLE 12 volume with the impregnate obtained. The closed autoclave was gradually heated in 63 min. to a maximum pressure of An impregnated mass obtained by mixing 50 g. of spherical l60 C., during which the maximum pressure observed was 34 amorphous silica (specific surface 200 sq.m./g. with a solution atm. Then the impregnate was removed from the autoclave via of g. of copper nitrate [Cu(NO -3H O] and 29 g. of urea a valve, cooled and dried for 88 hr. at 200 C. to give a catalyst in 360 ml. of water was heated for 100 hr. at 88 C. in a closed having a nickel content of 38.6 percent. Activation of this 250-ml. glass recipient as described in example 1. Then the catalyst was achieved by reducing it for 4 hr. in a tube furnace substance obtained was dried first for 8 hr. at 120 C. and then at 450" C. and in a hydrogen flow at a rate of 60 l./hr./g. for l6 hr. at 200C. to obtain acatalyst with acopper content nickel. The properties of the activated catalyst are shown in 5 of 9 percent. The catalyst could be activated at a temperature table of 500 C. without suffering appreciable sintering. This ac- TABLEI Catalyst Experiment Example- Properties A B C 1 2 3 4 5 6 7 8 9 10 11 Percentage nickel (1) 42.6 21.3 19.1 10.3 9-6 10.6 19.0 9.8 9.7 18.1 18.7 16.0 19.8 38,6 Total surface, m. /g., catalyst (2) 11 120 34 229 368 Specific Ni-surfaco, mJ/g. Ni total N1 (3 68 60 130 225 322 265 225 245 291 238 237 244 214 157 Mean size of the Ni erystallites:

(a) By ma netic measurements (4)- (8) (8) 2 A 4 A 26 A (b) By hy rogen adsorption (5), A.- 58 70 14 15 12 14 l7 11 13 13 14 15 15 21 (o) By electron microscopy. A 2 2 2 Degree of reduction percent (6) 90 98 42.6 75 93 89 91 63 88 74 75 87 76 77 Activity (benzene) (7) 0.5 2.8 3.2

i. The percentage Ni was determined before activation. tivated catalyst was suitable for the selective hydrogenation of 2. The total surface m.*/ g. of the catalyst was determined by Oil n fats. adsorption of nitrogen at 78 K., cf. S. Brunauer, P. H. Emmett The details of examples l3 to 34 are given in table ii. Examand E. Teller,J.Am.Chem. Soc. 60, 309(l938),and cf. B.G. ples of reactions which can be catalyzed by the catalysts Linsen, Thesis Delft (Netherlands), I964. prepared in examples 13 to 34 are also given in table ii.

3. The specific surface of nickel was determined by means The procedure used, except where noted in table II, was as of hydrogen chemosorption, cf. 1. W. E. Coenen, Thesis Delft follows: (Netherlands) i958 and 8.6. Linsen. loc. cit. The carrier was impregnated with an aqueous solution of 4. Ci. l. W. Selwood Adsorption and collective paramagthe salt and the precipitate. The impregnate was placed in a nctism. Academic Press Inc., New York, I962. glass bottle. The opening of the glass bottle was covered by a 5. Cf. l. W. E. Coenen, loc. cit. glass plate of weight 83.5 g. The bottle was heated for time 6. The degree of reduction (ratio reduced nickel/total (hr.) at a temperature T (C.) and the carrier containing the amoun nick l) wa ine y r cing the composition precipitated metal was heated for 6 hr. at l20 C. and then 24 under standard conditions (4 hr. at 450 C., H flow of 60 hr. at 200 C. l./hr.) and determining the amount of nickel metal by treating It should be noted that a surprising feature of nickel th catalyst with a 0 Lime" catalysts (e.g., example 14) prepared according to the inven- 7. The benzene activity is determin d by hy rogenati n of tion is that they show considerable activity as catalysts for the gaseous benzene y a known unt of catalyst under f isynthesis of ammonia. Similarly iron catalysts prepared acdard conditions. The specific reacti n rat benzene flctlvlcording to the invention show surprisingly increased activity in ty) is defined as the number moles benzene converted per the synthesis f m i TABLE II Salt Carrier Preelpitant Ratio Weight] Weight] Weight] (eq.) H2O, Formula grams Name grams Name grams to salt ml. t '1 Catalyst for- 1 3 35... N1(NO3)z-6Hz0 3.6 1 180 80 92 Hydrogenation.

14 Same as above 5.4 1.5 180 80 92 N2+3H2 ZNH; 16". UO2(OOC'CH3)22H2O 5.7 4 80 92 Acetaldehyde to acetic acid. 1 C (N() .3H2O 11.2 4 120 80 92 Solution hydrogenation of oils and fats. 17. CB(S04)z-4H2O 7.5 4 100 80 92 Synthesis ofHON. 18- VOSOyliHzO 39.8 4 150 80 92 o-Xylene oxldative. 19. Cr(NO;)s-9H1O 24.3 4 80 92 Dehydrogenation. 20 0], 0.6 4 20(2) 80 92 Polymerisation of C2H2- 21 Nd(N0 .5H20 7.5 4 57(2) 80 92 Promoter. 22 CO(NQ3),.CH2() 14.5 4 80 92 Hydrogenatiomegof enzene. 23 IF NO '9 O 26.3 25 do 23.4 4 (3) 80 92 N 3H 2N1;

. Sa oe a iib l e 26. 3' .....do.. 25 HMT(4) 27.4 4 145(5) 80 92 2+ 2 a 26.3 -(10 25 Forrita- 25 4 75(6) 80 92 (13).

m 6. 26.3 do 25 Acct/ii 46 4 (7) 80 92 m B- 27 N NO 61120 17.5 Norit (8) 25 Urea... 14.5 4 40 80 92 Hydro enation. 2s sa ine sfibovs 17.5 Silica 9 25 Was. 14.5 4 as so 92 Do do 17.5 Alumina 25 d0 14.5 4 50 80 92 Do. ...do. 17.5 Silica (11). 25 ..do. 14.5 4 55 so 92 do 17.5 Ti02(l2) 25 -do 14.5 4 40 so 92 ogl gwm 1 4i Silica (1) 25 ...do 62.6 4 100 80 92 lgegigacgaticzn. t l t VOSO -5H 0 6. x on e. ouene o S1101, 4 2 7.5 ml 25 6l'1 4 50 80 92 benzoic acid). Nickel, 17.5 ..-do 25 ...do. 14.5 11 120 75 l. Commercial amorphous spherical silica with a specific surface area of 200 mF/g.

2. in these examples a smaller glass bottle was used and consequently a smaller glass plate was used than described.

3. The iron nitrate was added in 60 ml. and the urea in 60 ml. acidified to pH 3.5 with nitric acid.

4. Hexamethylene tetramine.

5. The iron nitrate was added in 60 ml. and the HMT in 85 ml. acidified to pH 3.5 with nitric acid.

6. The iron nitrate was added in 50 ml. and the formamide in 25 ml. acidified to pH 3.5 with nitric acid.

TABLE III Reaction Reac- S02 Air term 801 tion flow, flow, peraconvertime, Space ml. ml ture, sion, rninvelocity SIP STP C. percent utes GHSV 1. Catalyst prepared according to 27 147 450 98 00 2,15 3 Example 35, 11.2% V205; 12.4% 27 147 460 08 50 2, 644'. K; 76.4% SlOz 5.0 g. (10.0ml.) 108 590 450 97. 3 11 10, 161; 205 450 98 2b 5, 080 2. Commercial catalyst, 8.2% V205; 8.3% K20; 61.6% Slo: 5.2 (9.9 ml.) 4.6% V; 6.0% K 61.6% 102... 27 147 450 70 60 2, 570

7. The iron nitrate was added in 50 ml. and the acetamrde in EXAMPLE 36 75 ml. acidified to pH 3.5 with nitric acid.

8. Commercial carbon black with a specific surface of 355 m."/g.

9. Commercial macroporous silica with a specific surface of 290 mF/g.

10. Commercial alumina (M 0 prepared by flame hydrolysis of AlCl and with a specific surface of l 12 mF/g.

l 1. Commercial macroporous silica with a specific surface of 30 mI /g.

l2. Commercial titanium oxide prepared by flame hydrolysis ofTiCl and with a specific surface of 49 m. /g.

l3. Formamide decomposes at room temperature but the pH of the solution is such that it can only be used with metals, such as iron, that precipitate when the pH is at such pH levels. r

This low pH precipitation also means that iron salt solutions, as is well known, must be maintained at even lower pH levels by, for example, addition of nitric acid.

EXAMPLE After mixing 75 g. of a spherical amorphous silica, having a specific surface of 200 m. /g., with a solution of 63 g. of vanadyl sulfate (VOSO 5H O) and I 19.4 g. of urea in 3l5 ml. of distilled water, the impregnate obtained was heated in a glass vessel for 6 hr. at l00 C. in nitrogen-steam flow after which the product was dried for l6 hr. in an oven at 200 C. 36.5 g. ofa sieve fraction of 400-600 micron was impregnated with 5.49 g. potassium sulfate (K 50 in 60 ml. of water and dried for 64 hr. at 120 C. and then for 2 hr. at 500 C.

The catalytic activity of the V O K SO silica system obtained was determined for the S0 oxidation process by passing a mixture of air and sulfur dioxide through a tube reactor with a diameter of l2 mm. and a height of 300 mm. filled with 5.0 g. (l0.0 ml.) of said catalyst placed at a height between 45 and I33 mm. measured from the bottom of the reactor at temperatures of 400 and 450 C.

The leaving gas mixture was passed through an aqueous After mixing I00 g. of a spherical amorphous silica, having a specific surface of 200 m./g.. with a solution of g. of nickel nitrate [Ni( NO 6H O] and 60 g. of urea in 800 ml. of distilled water, a H. autoclave was filled for 50 percent ofits volume with the impregnate obtained.

The closed autoclave was gradually heated during 58 minutes to a maximum temperature of l70 C. This temperature was maintained during 60 minutes, after which the autoclave was cooled to 50 C. over 128 minutes. The maximum pressure observed was 8 atm. Then the impregnate was removed from the autoclave, and dried for 43 hr. at 200 C. to give a catalyst having a nickel content of 9.4 percent. Activation of this catalyst was achieved by reducing it for 4 hr. in a tube furnace at 450 C. and in a hydrogen flow at a rate of 60 l./hr. per g. nickel.

EXAMPLE 37 After mixing g. of a spherical amorphous silica, having a Jspecific surface of 200 mF/g. with a solution of H25 g. of

nickel nitrate [Ni(NO 6H O] and 36 g. of urea in 600 ml. of distilled water a 1-]. autoclave was filled for 75 percent of its volume with the impregnate obtained. The closed autoclave was gradually heated in 52 minutes to a maximum temperature of I40 C. This temperature was maintained during 9 minutes and the maximum pressure observed was 13 atm.

Then the impregnate was removed from the autoclave via a valve, cooled and dried for 48 hr. at 200 C. to give a catalyst having a nickel content of I59 percent.

EXAMPLE 38 The ZrO /SiO catalyst prepared according to example 32 was tested on the vapor-phase dehydration of isopropanol.

The results obtained are given in table lV.

Comparative experiment D was prepared by adding dropwise with stirring hot IN NaOH to a suspensionof 25 g. silica (same as used in ex. 32) in an aqueous solution of 42 g. ZrOCl 8HO.

TABLE IV Catalyst Feed Composition, Pretreatment isopro- Currier percent panel gas Yields of propenc in percent Quantity, Grinding (1 ml. grams Code Zr 840 hour), r.p.m. Thermal treatment hour l/hour C. C. C. C.

Ball mill 140 fihours at 750 C. in air. 1. 90 6 47 98 ca. 100 EX-32 54 ....d0 20hoursat750C.lnair. 1.90 e 2 21 08 NM 2.0 D 20.8 47.6 Ball mill 140 1.90 6 1 12 52 93 190 220 250 280 50 C. C. C. C. C.

2.0 n 20.8 47.6 6hoursat750 c. in air 1.00 6 1 2 7 13 1g Table V gives further examples of supported catalysts that can be prepared according to the invention and reactions which the catalysts can be used to catalyze.

1 l. Dimethylacetamide. l2. Dimethylformamide. i l -lexamethylene tetramine.

TABLE V Metallic catalytic Example of reaction Example agent Carrier Precipitant Salt catalyzed 39 Cobalt Alumina Urea C(N0a)z.6HzO Hydrogenation (1). 40 d0 Magnesium do.. C0(NO3)2.6H20 Reduction (2).

hydroxide carbonate. 41 Iron/nickel Silica ..do Nl(NO.-i)z.6HzO Nz+3H2- 2NI-I FQ(NO3)3.OH2O 42 Chromium (oxide)... Alumina. CrCl; Dehydrogenation (3). 43. Ruthenium .do RuCl; C0+Hz CH4 44 Molybdenum (4) CHaOH HCHO (l5).

(oxide) iron oxide. 46 V Alumina do V0504 }0xidation (6). 46 {Tin oxide. SrtClz-ZHzO Oxidation V 0 S04 A110: do. o AMSOD; Oil washing. 48 Molybdenum (oxide) do Acrolein acrylobismuth oxide. nitrile. Molybdenum zinc do ..do (9) 50.-

Tun sten zinc do (10) '%i56 %0 0... 3 3- 2 52 dam Fe(NO3)39HzO }Oxidat1on of NIH.

. do CdClz-HzO Fatty alcohols from fatty acids. 54. do Co(N0a)2.6H O Hydrogenation.

. C0(NOa)z-6H2O Zn(NO3%z.6H28 }Hydrogenation.

EI(NO3)2.5H1O Fe(N0 .9HzO C0+H2O-CO2+H2 DMF (12)-.. Same as above).

Urea I: iDehydrogenation. do Hi'OClz-SHzO Cracking of hydrocarbons. !12 Ga ium ..d0 do G8.(N0 )z do n a Oxidation. d0 Ni(N03)2.6H20 (JO-CH4 HMT (13). Same as above-. Urea do Th(NOa)4.6H2O Fischer-Tropsch.

-(10 Yb(N03)3.5H2O

do Synthesis of methane.

Pressure hydrogenation of fuels. Dehydrogenation. Catalytic reforming. Pressure hydrogenation of coal. 74 Antimony do. Oxidation of ethylene. 75 Smmdium. Silica..- -do SC(NO3)3-9H2O Samarium. .do do Sm(NO;) .5HgO Thallium do do TlCli 1. After activation at 500 C. for 4 hr. with hydrogen such a We claim:

catalyst is more active for the hydrogenation of benzene than a catalyst prepared by boiling an ammoniacal solution of cobalt nitrate to precipitate the cobalt in an alumina support.

2. For example reduction of azelaic acid dinitrile in ammonia and hydrogen.

3. For example conversion of cyclohexane or n-hexane to benzene.

4. A solution obtained by reducing Na MoQ, with iron and HCl and then filtering off excess iron is used.

5. Such a catalyst after activation at 500 C. for 4 hr. in air gives a much higher conversion rate per unit weight molybdenum than a commercial catalyst.

6. For example in the oxidation of o-xylene such a catalyst is more selective than a commercial catalyst.

7. For example in the oxidation of toluene to benzoic acid such a catalyst after activation is more selective and more active than a tin vanadate catalyst prepared according to J. K. Chowdhury and S. C. Chowdhury, J. Indian Chem. Soc., 11, 194 (1934).

8. A solution of Na MoO is reduced with zinc and filtered. To the filtrate is added Cr(NO -b9l-i O.

9. A filtrate after the reduction of Na MQO with zinc is used.

l0. A filtrate after the reduction of Na WO with zinc is used.

1. A process for preparing a catalyst, said catalyst consisting of a metallic catalytic agent on a particulate carrier selected from the class consisting of diatomaceous earths, pumice, por- 55 celain, silica, asbestos, alumina, kaolin, infusorial earth, magnesium sulfate, barium sulfate and magnesia, in which process I. said carrier is impregnated with an aqueous solution of a. a water-soluble salt of the metallic catalytic agent and b. a source of hydroxyl ions selected from the class consisting of hexamethylene tetramine, urea, formamide, dimethyl formamide, acetamide and dimethyl acetamide which on heating in aqueous solution develop hydroxyl ions;

2. said carrier impregnated with said aqueous solution is heated in an atmosphere whose partial water vapor pressure exceeds the partial water vapor pressure of the carrier by 0 to 200 mm. Hg to develop sufficient hydroxyl ions to precipitate the metal on the surface of the particles of said carrier without substantial loss by evaporation of the aqueous solution; and

2. A process as claimed in claim I in which the carrier im- 4. A process as claimed in claim 1 in which the particulate pregnated with said aqueous solution is heated in a sealed vescarrier is selected from the class consisting of silica and alusel to develop sufficient hydroxyl ions to precipitate said mina.

metal.

3. A process as claimed in claim 2 in which the carrier 5 5. A process as claimed in claim 1 m which sald metallic pregnated with said aqueous solution is heated at a temperacatalyuc age! mckel' ture from 100 C. to 200 C. and the mole ratio of said source ofhydroxyl ions to said metal is from 1:] to 4: l. 

2. A process as claimed in claim 1 in which the carrier impregnated with said aqueous solution is heated in a sealed vessel to develop sufficient hydroxyl ions to precipitate said metal.
 2. said carrier impregnated with said aqueous solution is heated in an atmosphere whose partial water vapor pressure exceeds the partial water vapor pressure of the carrier by 0 to 200 mm. Hg to develop sufficient hydroxyl ions to precipitate the metal on the surface of the particles of said carrier without substantial loss by evaporation of the aqueous solution; and
 3. said metal on the surface of said particle is converted by drying and activation to the oxidized or reduced state to provide a catalyst consisting of a metallic catalytic agent distributed uniformly and in a finely divided state with narrow particle size distribution on a particulate carrier.
 3. A process as claimed in claim 2 in which the carrier impregnated with said aqueous solution is heated at a temperature from 100* C. to 200* C. and the mole ratio of said source of hydroxyl ions to said metal is from 1:1 to 4:1.
 4. A process as claimed in claim 1 in which the particulate carrier is selected from the class consisting of silica and alumina.
 5. A process as claimed in claim 1 in which said metallic catalytic agent is nickel. 